Process, Materials, and Measurements

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54 PROCESS, MATERIALS, AND MEASUREMENTS

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FORMING (METAL)

Forming is the process of transforming a specified material into a desired shape.

This section describes processes for forming cold and molten metal.

Casting

is a process by which molten metal is poured into a mold and allowed

to harden.

Sand casting

involves creating a master pattern that is pressed into a bed of sand

mixed with a heat resistant binder, resulting in a single-use (expendable) sand mold.

The mold includes a sprue, which channels molten metal into the part cavity, runners

for distributing the metal throughout the mold, and vents that allow gases to escape.

After the metal cools and hardens, the mold is broken away to remove the part. Sand

casting requires secondary processes to trim away the sprue, runners, and other

extraneous parts.

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Investment casting

involves creating a master pattern made of a material that melts

or evaporates when subjected to heat. The pattern is packed in sand or dipped in

ceramic slurry. In the situations where ceramic is used, it is allowed to harden and

the mold is inverted, then heated, allowing the pattern to melt away. Molten metal is

poured into the mold. After the metal cools and hardens, the mold is broken away.

Investment cast parts require secondary processes to trim away extraneous parts.

SAND CASTING

Gate

Peripheral

Feeder Rings

Radial Feeders

to Mold Cavity

Vents to Exhaust

Air and Gases

Alignment

Pins

Mold Parting

Plans

Mold Cavities Formed

by Packing Sand

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Job on:93996

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175 Si

Dept : DTP D/

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Job on:93996 CTP Title : RP_Process Material Measurements Client : Pro_Vision

Scn :

#

175 Size : 146.05(w) 209.55(h)mm _M2_Mac D

Dept : DTP D/O : 16.12.05 (Job on:000000 D/O : 00.00.01 Co: CM0)

Pantone

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Manufacturing Process

Die casting

involves forcing molten metals into reusable molds using pressure.

Metals with lower melting points (aluminum, copper, zinc, etc.) are used with this

process. When the parts cool and harden, they require secondar y operations to

remove flash.

Contour roll forming

is a process by which metal strips or sheets are converted into

continuous section profiles through a sequence of mating rollers. Each set of rollers

in the sequence progressively bends the strip until it reaches the desired section.

This process adds strength and rigidity to flat materials.

CONTOUR ROLL FORMING

Step 1

Step 2

Step 3

Step 4

Step 5

INVESTMENT CASTING

Pattern Cluster Flask Molding Shell Mold

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Job on:93996 CTP Title : RP_Process Material Measurements Client : Pro_Vision

Scn :

#

175 Size : 146.05(w) 209.55(h)mm _M2_Mac D

Dept : DTP D/O : 16.12.05 (Job on:000000 D/O : 00.00.01 Co: CM0)

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56 PROCESS, MATERIALS, AND MEASUREMENTS

Deep draw (stamping)

is a process that produces hollow shapes from flat sheets of

metal. The process involves a punch pushing a blank sheet of metal into a cavity.

Secondary trim operations are often necessary.

Extrusion

is a process by which molten metal (usually aluminum) is forced through a

die to form a long continuous section profile. Tooling costs are lower when compared

to other processes, and little scrap is produced. Designing a part with a continuous

section is important in preventing curvature in the length. Extrusions can be cut to a

desired length, and secondary operations are used to polish or add features through

material removal.

Punch

Punch

Ejector

Blank

Cavity

DEEP DRAW (STAMPING)

Job on:93996

Scn :

#

175 Si

Dept : DTP

2

Job on:93996 CTP Title : RP_Process Material Measurements Client : Pro_Vision

Scn :

#

175 Size : 146.05(w) 209.55(h)mm _M2_Mac D

Dept : DTP D/O : 16.12.05 (Job on:000000 D/O : 00.00.01 Co: CM0)

Pantone

109 U

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Manufacturing Process

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Job on:93996 CTP Title : RP_Process Material Measurements Client : Pro_Vision

Scn :

#

175 Size : 146.05(w) 209.55(h)mm _M2_Mac D

Dept : DTP D/O : 16.12.05 (Job on:93996.C1 D/O : 23.12.05_M2)

Pantone

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Forging

is a process of compressively deforming metal (heated or cold) between two

dies using impact or pressure. Forging can be used to form parts of almost any size

and shape and is commonly used for tools and fasteners.

Hydroforming

is a process for creating complex formed metal parts, without the need

for costly matched die pairs. The process utilizes pressurized liquid to force sheet

metal into a single die cavity.

Spinning

is a process for producing hollow rounded shapes by forcing a spinning

metal blank against a pattern. This process yields accurate and cost-effective parts.

SPINNING

Headstock

rotates

workplace

Spinning tool

Tailstock

Tool rest has

protruding pins

serving as pivots

for spinning tools

Blank

Chuck

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